Process of making compound metal bodies.



J. F. MONNOTP PROCESS OF MAKING COMPOUND METAL BODIES.

Patented Mar. 30,

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, APPLIUATION FILED MAY 23, 1906'. 91 6,471 Patented Mar. 30, 1909.

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JOHN FERREOL MONNOT, O F NEW YORK, N. Y., ASSIGNOR TO DUPLEX METALS COMPANY,

OF NEW YORK, N. Y., A CORPORATION OF NEW YORK.

PRQCESSOF MAKING COMPOUND METAL BODIES.

Specification of Letters Patent.

' Patented Marcheo, 1909.

Application filed. May 23, 1905. Serial No. 261,739.

{ed certain new and useful Improvements in Processes of Making Compound Metal-Bodies,

of which the following is a specification accompanied by drawings.

My invention'relates to improvements in processes of making compound metal bodies, such bodies or'aiticles comprising. ingots, plates, sheets, rods, tubes, wire, structural shapes and other articles composed of layers or strata of unlike metals firmly and autogenously welded together.

My present invention consists in the novel process herein described for producing such articles; all as norefullyhereinafter set forth, matters of novelty being particularly pointed out in the appended claims.

Compound articles composed of unlike metals welded together may be used to great advantage in a variety of arts and for many different purposes as combining the spccilic advantages of the componentunlike metals. For example, plates, sheets, etc., composed of a strong but readily oxidizable metal, such as iron or steel, covered with an impervious coherentcoating of copper or other less oxidizable metal, may be used to great advantage in 'lieu of ordinary iron or steel sheets, plates, etc.,..wherever such articles are to be exposed to the weather, air or other oxidizing influences, or to the action of corroding liquids, gases, vapors, foods, etc, which readily attackiron or steel, but do not attack at all, orat least to so serious an extent, the coating metal employed. Such articles com- )osed of copper, brass, silver, aluminum, etc.,

acked with iron or steel may be,used with great advantage where considerable strength electrical conductivity of copper, aluminum,

etc., with the great strength of steel. Man other such uses might be mentioned. In a 1 such cases, it is a prime requisite that the "ferrous and non-ferrous metals shall be so inseparably united that a compound ingot formed by joining them shall be capable of Working great extension or working, as by rolling, drawing, spinning, etc., to make thin sheets, rods, angles, tubes, Wire, etc., without separation of the united layers, without development of seams, )ores, flows, etc. and it is 111 practice desirab e that during such working the strata of the joined metals shall maintain substantially their original relative proportions, even down to the-thinnest extended article produced.

The object of my present invention is to devise a method of making compound ingots of this character from such pairs of unlike or chemically different metals as steel and copper, steel and brass or other copper alloys, steel and silver, steel and aluminum, or indeed any-other air of ferrous and non-ferrous metals; to orm such bi-metallic ingots of any desired shape or dimensions and with any desired relative proportions of the component "metals to produce such a strong, autogenous and weld-like union betweenthe unlike metals as shall be incapableof separation by heat or mechanical stress, and shall be adapted to permit indefinite co-extension of the joined metals in a compound ingot by any, of the ordinary methods of with said union extending throughout an persisting at all meeting points of the joined metals, and with the same relative proportions of the component unlike metals in the extended were as in the original compound ingot; to produce such compound ingots as shall be susceptible of coextension with the same case as ingots of simple metal; tov produce in the coextended ware derived therefrom articles comparable in price with ordinary coated metals, like electroplated,

tinned and galvanized ware while far supeflaws, blisters or points of separation, and

shall be weld-united with the base throughout; and it is, further, my object in said method to accomplishthese desirable ends and others, by a simple, cheap and easy process requiring no highly skilled labor.

Suitable apparatus for carrying out the process is'shown in the accompanying drawings, in Whicl1,-

Figure 1 is a vertical sectional view of a suitable press for carrying out the process; Fig. 2 is a horizontal sectional view of a suitable-mold'for carrying out the process; Fig. 3 is a vertical longitudinal sectional view of the mold on the lines 2 of Fig. 2, looking in the direction of the arrows; Fig. l is a vertical transverse sectional view of the mold on the line as at of Fig. 2 looking in the direction of the arrows; Fig. 5 is a vertical transverse sectional view of the mold on the line y y of Fig. 2, looking in the direction ofthe arrows; Fig. 6 is a vertical sectional view of another form of mold; Fig. 7 is a modification of said mold; Fig. 8 is a top plan View, and Fig. 9 is horizontal sectional view on the line a a of Briefly stated, my process consists in thoroughly cleaning a surface of a body of the more infusible metal intended for the base or core of the finished compound in 'ot, said body being in the form of a billet, s ab, ingot, bar or other commercial form; bringing the billet to a suitable high temperature by any method of heating in which oxidation or other contamination of the cleaned surface is prevented; contacting therewith, as by casting on, a highly heated molten metal in pro er quantity to form a layer or stratum of t e desired thickness; compressing the two metals together while still hot and in a more or less fluent condition, thereby completing the weld and sup ressing all blowholes, flaws or other de acts which might remain in the cast coating metals; and thereafter extending the compound ingot to produce coextended ware such as plates, sheets, tubes, wire, etc., comprising the joined metals, inseparably united.

I have found that in order to perfectly weld two unlike ,metals of such different character as steel and copper, that all oxidation or other contaminatlon should beprevented on the surface of contact, that such metals should be presented to each other with absolutely metallic surfaces; and that the metals should be subjected to pressure at all points of contact While the union or weld 1s forming. Pressure however and temperature are in some degree interchan cable and the higher the eat of the meta s to be united, the lower the pressure necessary to obtain a perfect weld.

In carrying out my process, it is important that the core or Y base used -while being heated up to the temperature necessary for the desired'union shall be so heated as to preclude all oxidation or contamination, this'being particularly necessary in the case of such an oxidizable metal as steel. Many different ways of performing such heating may be used. The core may be simply placed in the ingot mold which is later to be used to form the compound ingot, and there heated in an atmosphere of a gas which .is indifferent at the temperature employed,

such as carbon monoxid, carbon dioxid, etc. Any other receptacle, such as a simple tube or chamber may of course be. used, but in such case the core must be transferred to the mold when hot without permitting access of air to the cleaned surfaces. If desired, an electric current may be used Ior heating in these receptacles. Or the clean core may be plunged in a molten bath of the unlike metal to be used for coating and heated therein before transferring to the ingot mold.

Any suitable apparatus may be utilized illustrated in the drawings apparatus which will operate satisfactorily and well. Preferably the core metal is placed in a suitable mold so constructed that the molten coating metal may be oured in and around the core.

is movable, whereby pressure may be applied to the contents b means of a suitable press.

For making bi-metallic slabs to be used afterward for the'production of plates, sheets erally required on one or-two sides, a mold may be used such as illustratedin Figs. 2, 3, 4 and 5. This mold is preferably of rectangular section and of such construction as to fit in the dies of the hydraulic press illustrated in Fig. 1. In the construction means of bolts to the two ends e e which are preferably provided with flanges for the insertion of the bolts. In order that the mold may be easily taken apart, key bolts a are provided. The top 0 of the mold in this lnstance is free to move inward between the fixed sides a a and ends e e in which it should substantially exactly fit. The top 0 is suitably prevented from moving 0 tward as by means of the two swinging blo ks d. A runner x isprovided extending through one from said runner substantially to the top and bottom of the mold whereby the metal through the runner m and its branches to the top and bottom of the core which is placed in the mold.

set in the mold by removing the top plate 1; and suitable means are provided for supdistance above the bottom so that the molten metal for the coating may be oured under the core. 1' are provided of a length substantially for the core. The top plates is also sup ported above the top of the core by studs 7, thus leaving on each side-of the core a space for the coating metal.

Obviously if the 'mold and core were to be set on edge in a suitable die, the core should for carrying out thls process, but I have The mold is a so preferably constructed insuch a manner that a portion of the same illustrated the two sides a a and the bottom, I) of the mold are suitably secured as by I porting the core in the mold at the desired and the like, in'which the coating is genside a of'the mold, and branches :rextend may be run into the funnel F and thence I The, slab O for the core of suitable size is In this instance smal studs I equal to the thickness desired for the coating also be arranged in the mold in such manner that the molten metal may be poured at each side of thesame. The top 0 of the mold is then placed in position and the swinging blocks (1 are turned to maintain the top in position. The mold and its core are then heated according to one of the methods described for preventing oxidation. For instance, the space between the inside of the mold and the core may be filled with carbonic acid gas or any other neutral gas in any suitable manner to prevent oxidation of the core metal. Thecore and mold are then suitably heated to a sufficiently high temperature so that they will not chill the molten coating metal too rapidlywhen poured in, and so that condition for a time.

the latter may remain in a fluent or plastic When the core is at the desired temperature the mold is set on end and the molten metal for the coating of a different kind from the core is poured through the funnel F and the runner a; into the spaces left between the core and the inside surface of the mold. The mold is then carried rapidly to the dies of the hydraulic press illustrated in Fig. 1 and placed between the dieblocks S .S. Preferably a wedge VF is provided, with suitable actuating. means, for holding the mold firmly in place upon the base plate 8. Pressure is applied to the material in the mold by means of the ram R which bears upon the top plate 0 of the mold and forces it down into the mold and thus strongly compresses the two metals together on all surfaces of contact, the fluent coating metal acting to transmit pressure like a fluid, causing a perfect weld on all the contact surface of the core and coatin metal and suppressing all blow-holes or 0t or defects in the cast coating metal. When the pressure is, released and the bi-metallic ingot produced is sufliciently cold, it is taken out of the mold and treated by re-heating and rolling for finished roducts of the desired character. It is evi ent that the different ways described for protecting the core metal from oxidation during the heating are applicable in any case as desired.

If it is desired to make ingots or billets for bi-metallic wire or other articles requiring a uniform and continuous coating a mold such as illustrated in Figs. 6, 7, 8 and 9 may be used. This mold is shown of circular cross section, but it of course may be made square, rectangular, elliptical, or any other desired section. It is preferably made in two parts- I A suitably secured together as by means of bolts, and in this instance a double runner x is provided for casting the coating metal substantially equally around the core A. As. shown, the runners a2 extend down through the-sides A of the mold and communicate with the interior thereof at different heights. The two portions A of the mold having been bolted together, the mold is then set on its base B and the core A is centered in the mold as by means of the studs d. On top of the billet coreA is placed a block Dof the same size as the core and around block is, placed the sleeve or bushing E, which fits exactly around it and inside the mold and projects out of the top of the mold. Upon the top of the mold are placed top plates A and A having openings registering with the runners x. The mold and billet core are then heated in one of the ways described for preventing oxidation, as for instance, the interior of the mold between the core and the sides may be filled with carbonic acid gas or other neutral gas and the core and mold are heated as described to a substantially high temperature which will not chill the coating metal too rapidly when it is poured in. ten state of a different kind from the core is then poured through the runners x to fill the space around the core. The mold and core are immediately carried beneath the piston of a suitable hydraulic press or other kind of press, and pressure is applied to the top of the sleeve E which forces the semi-liquid coating metal longitudinally and compresses The coating metal in a molit strongly against the surface of the core metal, causin them to weld to ether and suppressing all blow-holes and other defects in the coating metal. A portion of the ram F of a suitable press is shown bearing upon the sleeveE in Fig. 6. The length of the block D is such that when the sleeve E is forced down by the action of the press, pref erably all the coating metal is forced off of said block and compressed on the core A. When the bi-metallic ingot or billet so produced is sufficiently cooled it is removed from the mold and is then ready to be treated by re-heating and rolling to obtain any desired bi-metallic products.

In some cases, I have found it useful to of the alkalies (waterglass) andaluminum owder will give good results. This particuar mixture possesses the additional advantage that 1n contactwith a molten coat ing metal, such as copper, any 'oxid which may be present in or on it, is reduced. The alumina formed slags off with the silicate. A core so painted may be very conveniently heated in many ways without fear of oxidation or'other deleterious contamination.

Obviouslythe apparatus for carrying out this process may vary widely and different modes of operation may be found for producing the same ends, by substantially the same steps, therefore, without enumerating all the equivalents of this process, I claim and desire to obtain by Letters Patent the following 1. The process of producing compound metal bodies comprising unlike metals welded together which consists in placing a body of ferrous metal in a mold, casting thereagainst a body of molten non-ferrous metal of high melting point, and compressing the molten. metal and solid metal together while said molten metal is in a fluent condition and adapted to transmit pressure to all abutting. surfaces of the two metals.

2. The process of producing compound metal bodies comprising steel and an unlike metal welded together which consists in placing a body of steel in a mold, casting thereagainst a body of molten non-ferrous metal of high melting point, and compressing the molten metal and solid metal together while said molten metal is in a fluent condition and adapted to transmit pressure to all abutting surfaces of the two metals.

3. The process of producing compound metal bodies comprising steel and copper welded together which consists in placinga bodyof steelin a mold, casting thereagainst a body of molten copper and compressing steel and copper together while the copper is in a fluent condition and adapted to transmit pressure to all abutting surfaces of the two metals.

4. The process of producing coextended compound metal-Ware composed ofunlike metals welded together which consists in placing a body of a ferrous metal in a mold, casting thereagainst a body of molten nonferrous' metal of high melting point, compressing both metals together while the molten metal is in a fluent condition and adapted to transmit pressure to all abutting surfaces of the two metals, and thereafter coextendin while stil in a heated condition.

'5. The process of producing compound metal bodies of unlike metals welded together, which comprises placing a body of ferrous metal within a suitable mold, heating said metalto a suitable temperature in such manner as to prevent oxidation, run ning into the mold between the said metal body and the side of the mold a molten non ferrous metal of high melting oint, and forcing the two metals together y pressure apthe compound ingot so formed' to the entire abutting surfaces of the metals,

and thereby welding them together and suppressing any flaws between them.

7. The process of producing compound metal bodies com rising a ferrous and a nonferrous metal we ded together, which comprises casting one such metal against an oxid free surface of a body of the' other metal heated to a suitable temperature, applying pressure .to the molten metal while the same is in arfi uent condition and adapted to transmit pressure to the entire abutting surfaces of the metals, and thereby welding them together and suppressing any flaws between them.

8. The process of producing compound metal bodies com rising a ferrous and a nonferrous metal we ded together, which comprises casting one such metal around and against a core of the other metal, applying pressure to the molten metal while the same is in a fluent condition and adapted to transmit pressure to the entire abutting surfaces of the metals, and thereby welding them to-,

getherand suppressing any flaws between them. v

9. The process of producing compound metal bodies com rising a ferrous and-a nonferrous. metal we ded together, which comprises casting the non-ferrous metal around and against a core of ferrous metal heated to a suitable temperature and having an'oxidfree surface for contact with the cast metal, a plying pressure to the molten metal while tf fe same 1s in a fluent" condition and adapted to transmit pressure to the entire abutting surfaces of the metals, and thereby welding them together and suppressing any flaws between them.

In testimony whereof I have signed this specification in the presence of two subscr1bing witnesses.

JOHN FERREOL MONNO T. lVitnesses: i

OLIN A. FOSTER-,- A. L. OBRIEN. 

